US20180248328A1 - Disk blank for producing commutator bars - Google Patents

Disk blank for producing commutator bars Download PDF

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Publication number
US20180248328A1
US20180248328A1 US15/755,152 US201615755152A US2018248328A1 US 20180248328 A1 US20180248328 A1 US 20180248328A1 US 201615755152 A US201615755152 A US 201615755152A US 2018248328 A1 US2018248328 A1 US 2018248328A1
Authority
US
United States
Prior art keywords
contact
disk
commutator
disk blank
carbon
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US15/755,152
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English (en)
Inventor
Martin Maurer
Florian Huber
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Schunk Carbon Technology GmbH
Original Assignee
Schunk Carbon Technology GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Schunk Carbon Technology GmbH filed Critical Schunk Carbon Technology GmbH
Assigned to SCHUNK CARBON TECHNOLOGY GMBH reassignment SCHUNK CARBON TECHNOLOGY GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HUBER, FLORIAN, MAURER, MARTIN
Publication of US20180248328A1 publication Critical patent/US20180248328A1/en
Abandoned legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/06—Manufacture of commutators
    • H01R43/08—Manufacture of commutators in which segments are not separated until after assembly
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R39/00—Rotary current collectors, distributors or interrupters
    • H01R39/02—Details for dynamo electric machines
    • H01R39/04—Commutators
    • H01R39/045—Commutators the commutators being made of carbon
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R39/00—Rotary current collectors, distributors or interrupters
    • H01R39/02—Details for dynamo electric machines
    • H01R39/04—Commutators
    • H01R39/06—Commutators other than with external cylindrical contact surface, e.g. flat commutators
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K13/00—Structural associations of current collectors with motors or generators, e.g. brush mounting plates or connections to windings; Disposition of current collectors in motors or generators; Arrangements for improving commutation
    • H02K13/006—Structural associations of commutators
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M37/00—Apparatus or systems for feeding liquid fuel from storage containers to carburettors or fuel-injection apparatus; Arrangements for purifying liquid fuel specially adapted for, or arranged on, internal-combustion engines
    • F02M37/04—Feeding by means of driven pumps
    • F02M37/08—Feeding by means of driven pumps electrically driven

Definitions

  • the present invention relates to a disk blank for producing commutator bars of a disk commutator, comprising a carbon mold body made of a carbon material for forming tread segments of the commutator bars and a contact arrangement made of a carbon and arranged on the carbon mold body and a contact material comprising a contact metal for forming connecting segments of the commutator bars.
  • Disk commutators are used in particular in fuel pumps for the electromotor drives of the fuel pumps, said disk commutators being assembled from commutator bars which comprise tread segments free of copper. By doing so, it is to be ensured that copper particles cannot be released due to abrasion of the commutator bars while operating the fuel pumps, said copper particles otherwise possibly causing electro-erosive processes between the carbon brushes and the commutator bars of the fuel pump.
  • the disk commutators assembled from commutator bars are produced based on disk blanks, which are formed annularly and are produced in a compression molding method based on a homogenized mixture of carbon-based powders, such as graphite or coke, and organic binding agents, such as resin or polymers.
  • a contact layer made of a metallic material preferably copper, is applied to the disk blank so that the commutator bars each comprise a layer made of carbon material for forming the tread segment and a layer of the metallic contact material formed thereon as a connecting segment after the separation, said connecting segment enabling electrically contacting the tread segments to the winding of the electric motor.
  • the object of the present invention is to propose a disk blank which enables producing safe-to-operate commutator bars.
  • the disk blank according to the invention comprises the features of claim 1 .
  • the disk blank according to the invention comprises a contact arrangement made of contact bodies distanced from one another via transition areas on the carbon mold body formed from the carbon material, said contact bodies being realized as contact-material mold bodies and being connected to the carbon mold body in a compression molding method in such a manner that the disk blank is realized as a multi-layer body, said carbon mold body forming a continuous first layer and said contact arrangement forming a second layer disrupted by the transition areas in such a manner that the transition areas do not comprise contact material.
  • the disk blank realized according to the invention enables, on the one hand, forming a composite between the contact arrangement and the carbon mold body simultaneously to producing the carbon mold body and the contact arrangement due to being realized as a multi-layer body produced in a compression molding method.
  • the transition areas form gaps between the contact bodies or the transition areas comprise a separating material between the contact bodies.
  • the disk blank comprises a transition zone between the carbon mold body and the contact bodies, said transition zone comprising the carbon material of the carbon mold body as well as the contact material of the contact bodies so that a particularly secure mechanical composite is enabled between the carbon mold body and the contact bodies having a transition, which is continuously formed due to the material mixing in the transition zone, from the thermic expansion coefficient of the carbon material to the thermal expansion coefficient of the contact material deviating therefrom and thus arising tensions, which can lead to delaminations, can be particularly effectively counteracted.
  • the contact bodies are realized as multi-layer bodies made of at least two contact layers, which comprise an inner contact layer for forming a contact body base and an outer contact layer arranged on the inner contact layer for forming a contact-body upper part, the thermal expansion coefficient in the contact body itself can be continuously differentiated as well as an electrical conductibility advantageously maximized in the contact-body upper part can be undertaken for a particularly secure contact between the commutator bars and a winding of the electric motor.
  • the contact material of the contact-body upper part comprises a higher percentage by weight of a contact metal than the contact material of the contact body base.
  • the contact material of the contact body base comprises a higher percentage by weight of carbon than the contact material of the contact-body upper part.
  • the contact material comprises copper or a copper alloy or silver or a silver alloy as a contact metal.
  • the contact material of the contact-body upper part and the contact material of the contact body base comprise different contact metals.
  • the commutator bar according to the invention comprises the features of claim 9 .
  • the contact body comprises a smaller extension in the tread direction of the disk commutator than the tread segment so that body edges of the contact body extending transversally to the tread direction are offset to the back with respect to cutting edges of the tread segment, and the tread segment comprises a tread protrusion protruding from the contact body.
  • the disk commutator according to the invention comprises an annular arrangement of the commutator bars arranged on a carrier body.
  • FIG. 1 illustrates a disk commutator having a plurality of commutator bars arranged on a carrier body in an isometric view
  • FIG. 2 illustrates a disk blank for producing the commutator bars illustrated in FIG. 1 in a bottom view
  • FIG. 3 illustrates the disk blank illustrated in FIG. 2 in a cross-sectional view
  • FIG. 4 illustrates a commutator bar separated from the disk blank illustrated in FIGS. 2 and 3 ;
  • FIG. 5 illustrates another embodiment of a disk blank in a bottom view
  • FIG. 6 illustrates the disk blank illustrated in FIG. 5 in a cross-sectional view
  • FIG. 7 illustrates a commutator bar separated from the disk blank illustrated in FIGS. 5 and 6 .
  • FIG. 1 illustrates a disk commutator 10 having a carrier body 11 , which is made of non-conductive plastic and which comprises eight commutator bars 12 in the example of the illustrated embodiment, said commutator bars 12 each being arranged such on the carrier body 11 that the tread segments 13 of the commutator bars 12 are arranged in a shared contact plane 15 of the disk commutator 10 with their contact surfaces 14 and can be contacted to carbon brushes not illustrated in this instance in this contact plane 15 .
  • the commutator bars 12 each comprise a contact body 16 on an underside of the tread segments 13 , said contact body 16 forming a connecting segment of the commutator bar 12 and being contacted to hook-shaped outer contacts 17 illustrated in FIG. 1 , which serve for contacting or receiving, respectively, a winding of an electric motor.
  • FIGS. 2 and 3 a disk blank 18 is illustrated, which serves for producing the commutator bars 12 illustrated in FIGS. 1 and 4 by separating the commutator bars 12 from the disk blank 18 .
  • radial separating cuts are carried out through the disk blank 18 for separating the commutator bars 12 so that the cutting edges 20 illustrated in FIGS. 1 and 4 are formed at the commutator bars 12 .
  • the contact bodies 16 are distanced to one another along the circumference of the disk blank 18 so that transition areas 21 forming gaps in this instance are formed between the contact bodies 16 , the thickness of the disk blank 18 ( FIG. 3 ) corresponding to the thickness of the cross section of a carbon body 22 in said transition areas 21 so that a cutting surface 23 corresponds to the cross-sectional surface of the carbon mold body 22 when carrying out a separating cut along a cutting line 19 falling in the transition area 21 .
  • the contact bodies 16 remain intact when carrying out the separating cut so that no particles of a contact material forming the contact body 16 can be released.
  • the disk blank 18 illustrated in FIG. 3 in a cross-sectional view is realized as a multi-layer body, the carbon mold body 22 forming the first layer and a contact arrangement 24 ( FIG. 2 ) formed from the contact bodies 16 forming a second layer in the illustration according to FIG. 3 .
  • the disk blank 18 is produced in a compression molding method, in which the carbon mold body 22 and the contact arrangement 24 assembled from the contact bodies 16 and formed on the carbon mold body 22 are produced simultaneously. This can be realized such, for example, that the carbon material, which is used for producing the carbon mold body 22 and which consists of a mixture of graphite powder and an organic binding agent, is added to a form and the carbon mold body 22 is subsequently pre-compressed.
  • the contact material is applied to the surface of the pre-compressed carbon mold body 22 in a defined manner via a mold die in order to form the contact body 16 .
  • the contact material comprises a portion of graphite so that graphite is present not only in the carbon material for forming the carbon mold body 22 but also in the contact material for forming the contact body 16 .
  • a contact material composition made up of 60% copper powder, 30% graphite and 10% organic binding agent, for example, has proven to be successful.
  • a carbon material composition made up of 80% copper powder, 15% graphite and 5% organic binding agent has proven to be advantageous.
  • a disk blank 26 which, as can be gathered in particular from FIG. 6 , comprises a three-layered assembly, which comprises a first layer formed as a carbon mold body 27 and which is provided with a double-layered contact arrangement 28 .
  • the carbon mold body 27 is realized in accordance with the carbon mold body 22 of the disk blank 18 in the instance of the present exemplary embodiment.
  • the contact arrangement 28 comprises a contact material layer 29 abutting directly against the carbon mold body 27 and an upper contact material layer 30 formed thereon, said contact material layers 29 and 30 each forming contact bodies 31 together.
  • the contact material layers 29 and 30 comprise different contact-material compositions, the contact material layer 29 comprising 60% copper powder, 30% graphite and 10% of an organic binding agent in the present instance; the contact material layer 30 comprises a composition of 95% copper powder and 5% graphite, a binding agent not being necessary in this instance due to the high amount of copper.
  • the disk blank 26 illustrated in FIGS. 5 and 6 is also produced in a compression molding method, in which transition zones 32 and 33 are formed between the carbon material of the carbon mold body 27 and the adjacent contact material layer 29 as well as between the contact material layer 29 and the contact material layer 30 , the layer material adjacent to each other being mixed in said transition zones 32 and 33 .
  • the contact material layers 29 , 30 comprise outer contours deviating from one another so that the contact bodies 31 are formed in a tiered manner having a contact body base 34 formed via the contact material layer 29 and having a contact-body upper part 35 , which is truncated in form in the present instance.
  • the truncated embodiment of the contact-body upper part 35 enables a form-fitting adjustment of the contact body 31 to an outer contact 17 of a disk commutator.
  • FIG. 7 illustrates, the nearly trapezoid embodiment of the contact body base 34 when seen from above enables a mostly large-surfaced coverage between the tread segments 38 and the connecting segment formed via the contact body 31 despite retaining a tread protrusion x between a body edge 39 of the contact body 31 and a cutting edge 36 of the commutator bar 37 , with which the tread segment 38 protrudes from the contact body base 34 .
  • FIG. 4 accordingly illustrates a tread protrusion x between a body edge 40 of the contact body 16 and the cutting edge 20 of the commutator bar 12 .

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Power Engineering (AREA)
  • Motor Or Generator Current Collectors (AREA)
  • Fuel Cell (AREA)
US15/755,152 2015-09-02 2016-08-19 Disk blank for producing commutator bars Abandoned US20180248328A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP15183488.4A EP3139455B1 (de) 2015-09-02 2015-09-02 Scheibenrohling zur herstellung von kommutatorlamellen
EP15183488.4 2015-09-02
PCT/EP2016/069706 WO2017036820A1 (de) 2015-09-02 2016-08-19 Scheibenrohling zur herstellung von kommutatorlamellen

Publications (1)

Publication Number Publication Date
US20180248328A1 true US20180248328A1 (en) 2018-08-30

Family

ID=54106158

Family Applications (1)

Application Number Title Priority Date Filing Date
US15/755,152 Abandoned US20180248328A1 (en) 2015-09-02 2016-08-19 Disk blank for producing commutator bars

Country Status (9)

Country Link
US (1) US20180248328A1 (pt)
EP (1) EP3139455B1 (pt)
JP (1) JP2018529194A (pt)
CN (1) CN107925209A (pt)
BR (1) BR112018004174A2 (pt)
HU (1) HUE047202T2 (pt)
MX (1) MX2018002437A (pt)
PL (1) PL3139455T3 (pt)
WO (1) WO2017036820A1 (pt)

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19543998B4 (de) * 1995-11-25 2007-07-05 Robert Bosch Gmbh Verfahren zum Herstellen eines Kommutatorringes für einen Kommutator
JP3805912B2 (ja) * 1998-11-13 2006-08-09 トライス株式会社 カーボン整流子
DE19925286A1 (de) * 1999-06-02 2000-12-07 Kolektor D O O Verfahren zur Herstellung eines Plankommutators sowie ein nach diesem Verfahren hergestellter Plankommutator
DE19956844A1 (de) * 1999-11-26 2001-06-13 Kolektor D O O Plankommutator, Verfahren zu seiner Herstellung sowie Leiterrohling und Kohlenstoffscheibe zur Verwendung bei seiner Herstellung
DE10115601C1 (de) * 2001-03-29 2002-09-05 Kolektor D O O Trommelkommutator sowie Verfahren zu seiner Herstellung
CN101055962B (zh) * 2007-05-28 2010-08-04 史文浩 圆筒式碳换向器及其制造方法

Also Published As

Publication number Publication date
HUE047202T2 (hu) 2020-04-28
EP3139455B1 (de) 2019-08-21
BR112018004174A2 (pt) 2018-09-25
JP2018529194A (ja) 2018-10-04
WO2017036820A1 (de) 2017-03-09
CN107925209A (zh) 2018-04-17
PL3139455T3 (pl) 2020-02-28
MX2018002437A (es) 2018-11-29
EP3139455A1 (de) 2017-03-08

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